EP2545245B1 - Dual ball upper internal blow out preventer valve - Google Patents
Dual ball upper internal blow out preventer valve Download PDFInfo
- Publication number
- EP2545245B1 EP2545245B1 EP11709296.5A EP11709296A EP2545245B1 EP 2545245 B1 EP2545245 B1 EP 2545245B1 EP 11709296 A EP11709296 A EP 11709296A EP 2545245 B1 EP2545245 B1 EP 2545245B1
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- EP
- European Patent Office
- Prior art keywords
- valve
- crank
- ibop
- valves
- actuator
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/10—Valve arrangements in drilling-fluid circulation systems
- E21B21/106—Valve arrangements outside the borehole, e.g. kelly valves
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B2200/00—Special features related to earth drilling for obtaining oil, gas or water
- E21B2200/04—Ball valves
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/8593—Systems
- Y10T137/87917—Flow path with serial valves and/or closures
Definitions
- This disclosure relates to the field of oilfield drilling equipment.
- this disclosure is drawn to an internal blowout preventer of a top drive system used in drilling rigs for the discovery and production of hydrocarbons from the earth.
- IBOPs Internal blowout preventers
- the IBOP includes a valve that can be closed in order to contain fluid from flowing out of the well. Regulations in some geopolitical areas require two IBOPs (referred to as an upper IBOP and a lower IBOP) at the top of the well, for safety redundancy. Both the lower and the upper IBOP are tested periodically, such as weekly, to confirm that both valves hold a sufficient pressure without leaking. Other than this periodic testing, the lower IBOP valve is typically used only in the event of an emergency, such as a well blow-out.
- the upper IBOP valve is also used as a mud saver valve to contain hydrostatic or mud pump pressure from above. That is, each time a stand of pipe (typically three pipe segments threaded together) is added to the string and lowered into the wellbore, the upper IBOP is closed prior to disconnecting the top drive from the drill string, in order to contain the drilling fluid or mud flowing through the top drive. With the upper IBOP closed, the top drive is disconnected from the drill string and the entire assembly is raised to accept a new stand of pipe.
- the upper IBOP valve may be cycled many times per day as a mud saver valve, in addition to weekly testing and emergency use.
- both the upper and lower IBOP valves are subject to periodic hydrostatic pressure testing, and a test failure requires immediate replacement of the valve, leading to lost drilling time.
- the upper IBOP valve in particular is subject to frequent repair or replacement.
- a typical known IBOP assembly includes both a lower IBOP and an upper IBOP, each IBOP including a single blow-out preventer valve.
- the two IBOPs may be coupled together through multiple separate assemblies.
- regulations require the redundancy of an upper and a lower IBOP, as a safety requirement.
- the seals on these valves are subject to high strain and wear, causing frequent failure.
- a back-up valve is always required, if one of the valves fails (such as failing a weekly pressure test), the backup is then put in operation only until it is possible to shut down the drilling operation to repair or replace the first failed valve.
- drill operations must be suspended while the entire IBOP unit is replaced or while repairs are performed. Neither of these options is particularly appealing, however, due to cost and loss of time on the drill site. Repair or replacement of an upper IBOP valve is a time consuming process.
- IBOP valves are important parts of a top drive system which is used to drill for oil and gas.
- Known top drive systems typically have an upper IBOP valve and a lower IBOP valve, as regulations require, which become parts of the drill string during drilling.
- Each IBOP typically has only a single valve.
- IBOP valves are used as pressure control valves in case of a pressure kick from the well bore.
- the upper and lower IBOPs are typically used in tandem to provide the required safety redundancy, which necessarily involves numerous additional pipe connections and steps, and adds additional length in the assembly.
- the upper IBOP valve is remotely operated and is also used as a mud saver valve when a drill string connection is broken to add a new section of drill pipe.
- the internal blowout preventer is a triple-valve internal blowout preventer having unitary construction.
- Each valve includes a tubular assembly having a central passageway with upper and lower seats mounted therein.
- Document GB 2 129 033 A discloses a single ball valve cooperating with a floating valve seat and having an actuator inside a blowout preventer.
- the invention provides for an internal blowout preventer for use in drilling operations with the features of claim 1. Embodiments of the invention are identified in the dependent claims.
- a dual upper IBOP valve having two ball valves within a single housing.
- This dual upper IBOP assembly provides a second redundancy in the system, by providing both a main upper IBOP valve and a back-up upper IBOP valve.
- An actuator sleeve may be provided to operate crank mechanisms for each valve, to open or close the valve as necessary.
- a dual upper IBOP valve with a quick engagement crank mechanism allows the upper IBOP to continue to be used even after failure of the first upper IBOP valve, by switching to the second upper IBOP valve.
- a dual upper IBOP can improve the drilling situation considerably by allowing the rig crew to schedule repair work on the problematic valve to a convenient time, rather than needing an immediate emergency repair or replacement.
- the dual upper IBOP valve disclosed herein is an improvement over the existing single upper IBOP valve and can be used as a direct replacement of either a single upper IBOP valve (which does not provide the second redundancy) or two single upper IBOP valves connected in series (which add considerable length and additional connections to the assembly).
- the second upper IBOP valve in the dual upper IBOP can be used, thereby saving valuable drilling time until a repair or replacement procedure can be scheduled.
- the dual valves can be operated such that only one of the two valves in the dual upper IBOP valve is functional at a time, and the other is set up as a back-up valve.
- the dual upper IBOP valve is a candidate to improve performance, efficiency, and reliability of top drive systems.
- a top drive system equipped with a new dual upper IBOP valve with its unique design allows the drilling crew to quickly switch to the back-up upper IBOP valve and continue drilling.
- the switch to the backup upper IBOP valve is achieved by disengaging the faulty upper IBOP valve and engaging the back-up upper IBOP valve with minimal effort and time. This capability allows the replacement or repair of the dual upper IBOP valve to be scheduled and performed when convenient.
- a dual internal blowout preventer for oilfield drilling operations includes two complete independent blowout preventer assemblies independently operable in a single housing.
- at least one of the internal blowout preventer assemblies is adapted to be operated remotely.
- both of the internal blowout preventers are adapted to be operated remotely.
- a single-end loaded, dual ball, upper internal blowout valve is provided for drilling operations.
- a quick change crank mechanism is also provided for use with a single end loading, dual ball, upper internal blowout valve.
- the internal blowout preventer (IBOP) for use in drilling operations includes a housing having first and second openings at opposite first and second ends of the housing, and having a flow passage between the openings.
- the IBOP also includes first and second valves located in the flow passage in the housing. Each valve is movable between an open position in which the flow passage is open and a closed position in which the flow passage is closed.
- the IBOP also includes an actuator assembly coupled to the housing for independently operating the first or second valve. The first and second valves are received into the housing through the first opening.
- FIG. 1 shows a drill string 2 suspended by a derrick 4 for drilling a borehole 6 into the earth for minerals exploration and recovery, and in particular the recovery of petroleum or natural gas.
- a bottom-hole assembly (BHA) 8 is located at the bottom of the borehole 6 and comprises a drill bit 10. In directional drilling, the BHA 8 may have a downhole steerable drilling system 9.
- the drill bit 10 As the drill bit 10 rotates down hole, it cuts into the earth allowing the drill string 2 to advance, forming the borehole 6.
- the drill bit 10 may be one of numerous types well known to those skilled in the oil and gas exploration business. This is just one of many types and configurations of bottom hole assemblies 8, however, and is shown only for illustration. There are numerous downhole arrangements and rig and equipment configurations possible for use for drilling boreholes into the earth with top drive systems 12, and the present disclosure is not limited to the particular configurations as detailed herein.
- FIGs 2 and 3 are side views of components of a drilling rig top drive system 12 according to an embodiment of the present invention.
- a dual ball upper internal blowout preventer (IBOP) 20 according to an embodiment of the present invention is mounted to the rig along with other components of the top drive drilling rig, including a yoke 17, a pipe handler frame 15, and a hydraulic cylinder 13 ( Figure 2 ).
- the dual ball upper IBOP 20 includes two ball valves 22, 24 inside a single housing.
- the first upper IBOP valve 22 and the second upper IBOP valve 24 are both adapted for controlling well pressure and drilling mud flow.
- Figure 2 shows the relative location of the upper IBOP valves 22, 24 with respect to the other drilling rig components.
- a single valve lower IBOP 300 with single ball valve 301 is connected below the dual upper IBOP 20. Below the lower IBOP 300 is a bell-mouth 302 which receives the top end of a pipe segment or pipe stand.
- the dual ball upper IBOP 20 is connected to the main output shaft 26 of the top drive system 12, and is exemplary of one manner in which this dual ball upper IBOP 20 may be implemented on a drill rig with a top drive system 12.
- the IBOP 20 is threaded directly to the output shaft 26.
- the output shaft 26 is rotated by the top drive 12.
- the dual ball upper IBOP 20 is not limited only to these types of drilling systems.
- the dual ball upper IBOP 20 with first and second valves 22, 24 is connected to the top drive system 12 and forms a part of the drill string, as indicated in Figures 2 and 3 .
- the dual upper IBOP 20 includes two separate valve assemblies 22, 24 and is referred to as a "dual" upper IBOP.
- the dual upper IBOP 20 includes a mud flow passage 28 through the center of the IBOP, along the central longitudinal axis of the IBOP.
- Each valve assembly 22, 24 can be rotated through 90 degrees to open or close the valve to allow or block mud flow through the IBOP 20.
- the dual upper IBOP 20 may replace an existing single upper IBOP valve in a typical drill rig. Further details of the dual upper IBOP 20 are described below, including the arrangement of the valves 22, 24, the actuating mechanism, the single-end loading capability, and the compact length.
- the dual upper IBOP valve assembly 20 consists of two substantially independent valve assemblies 22, 24 inside a single IBOP housing 23.
- the two IBOP valve assemblies 22, 24 each include a ball valve 30, 32, and the IBOP may be referred to as a dual ball upper IBOP.
- the valves 22, 24 could be plug valves or other suitable valves.
- the first valve 22 may be located at the top, above the second valve, and the second valve 24 may be located at the bottom, or vise versa.
- the dual upper IBOP 20 When the dual upper IBOP 20 is installed, one valve is identified as the primary valve, and the other valve as the back-up valve. Either valve may function as the primary valve.
- the first valve 22 is the primary functioning IBOP valve
- the second valve 24 is the back-up IBOP valve.
- valves 22, 24 may be ball valves 30, 32, as shown in Figure 4 .
- each ball valve 30, 32 is similar to a ball valve in a single upper IBOP valve.
- the valves 22, 24 may have other designs, depending on system requirements and interchangeability.
- the dual upper IBOP assembly 20 occupies the same space in the drill string as an existing single upper IBOP valve.
- an existing drilling rig with a single upper IBOP valve can be retrofitted with a dual upper IBOP 20 by simply removing the single upper IBOP valve and replacing it with the dual upper IBOP 20, without adding any additional length or width to the drill string.
- the ball valves 30, 32 each include a generally spherical ball 36, 37. Each ball is seated between a fixed seat 34, 35 and a floating seat 42, 43 with proper sealing arrangements.
- the fixed and floating seats provide arcuate surfaces that rest against the balls 36, 37 to trap the balls inside the IBOP housing 23.
- the fixed seats 34, 35 are fixed to the IBOP housing 23 such as by threads or other mechanical fasteners.
- the floating seats 42, 43 are biased against other components to apply a force to the respective ball 36, 37 to hold the ball in place between the two seats.
- one or more springs 38 such as a wavy circular spring or other type of spring, urges against the floating seats 42, 43, forcing the seat against the respective spherical ball 36, 37.
- the spring and floating seat thereby urge the ball against the fixed seat 34, 35 on the other side of the ball.
- the pressure from the wellbore lifts the ball 36, 37 from the respective fixed seat 34, 35 and presses the ball against the respective floating seat 42, 43.
- the contact of the ball against the arcuate surface of the floating seat creates a pressure seal along the contact area between the ball and the floating seat, to contain pressure from the well.
- the floating seat 42, 43 urges the ball 36, 37 against the fixed seat 34, 35 below the ball to create a positive seal.
- a mud flow passage 28 through the center of the IBOP continues through the ball and seat components.
- Each ball 36, 37 includes a bore 40 through the ball, and the bore can be aligned with the mud flow passage 28 through the IBOP to allow mud flow.
- the ball can be rotated through 90 degrees to move a solid side of the ball into the mud flow passage 28, blocking further passage of mud or other fluid through the IBOP 20 (shown in Figure 5 ).
- Each ball 36, 37 is connected to two internal crank assemblies, one on each side of the ball, identified as 41A and 41B respectively. It should be noted that in other embodiments, each ball may be connected to only one crank assembly. These internal crank assemblies 41A, 41B are located within the housing 23. Each assembly 41A, 41B includes an internal crank 51 connected to a universal coupling 53. The coupling 53 fits into a slot in the side of each ball. Each crank 51 has a hexagonal opening 50 on the outer side, facing away from the ball, for engagement with an external crank assembly which is used to rotate the ball between open and closed positions, as described in more detail below. In other embodiments, the opening 50 can take other suitable shapes other than hexagonal, such as the shape of a square, triangle, or star.
- the dual upper IBOP 20 includes two valves 22, 24 inside a single housing 23.
- the single housing 23 reduces the number of external connections or couplings that would otherwise be needed to connect two separate valve assemblies together.
- the housing 23 includes an upper end 46 and a lower end 47. The upper end 47 is toward the top drive system 12, and the lower end 47 is toward the borehole 6.
- Both valve assemblies 22, 24 can be loaded into the housing 23 from the same end, in one embodiment the upper end 46. That is, the dual upper IBOP valve assembly 20 has the capability of being assembled from one end of the housing 23, and as such be characterized as a "single end loading" dual upper IBOP valve. This capability is shown in Figure 4 , where both valves 22, 24 are loaded into the housing 23 through the upper end 46.
- the upper and lower ends 46, 47 each have an opening 46A, 47A that communicates with the mud flow passage 28 through the IBOP. Each opening may have internal threads 46B, 47B.
- the opening 46A and the mud flow passage 28 through the upper end 46 are wide enough in diameter to receive the valves 22, 24.
- the valve 24 can be received into the IBOP housing 23 through the opening 46A, arranged between seats 35 and 43, and subsequently the other valve 22 can be loaded into the IBOP and seated above the lower valve 24.
- a retainer ring 71 is provided above the valve 22, capturing the spring 38 between the ring 71 and the floating seat 42.
- the diameter of the opening 46A is selected to be wide enough to receive these valves and seats and corresponding components into the housing 23.
- the IBOP can be designed to provide single-end loading from either the upper end 46 or the lower end 47.
- the embodiment of Figure 4 provides loading from the upper end 46. In either case, the two valves are both loaded from the same end, and are functionally configured in the same way (as described in more detail below).
- the opening 47A at the lower end 47 of the IBOP is not limited by the size of the valves 22, 24. Because both valves 22, 24 are inserted through the opening 46A at the upper end, the diameter of the opening 47A at the lower end is not constrained by a minimum size to receive the valves. Instead, the diameter of the lower opening 47A is free to be smaller than the valves 22, 24. This freedom of design allows the lower opening 47A to be sized for a desired component below the IBOP 20.
- a lower single IBOP assembly 300 may be attached to the lower end 47 of the dual upper IBOP 20, between the IBOP 20 and the drill string.
- the lower IBOP valve 300 provides the required regulatory redundancy for safety.
- the lower IBOP 300 may be smaller in diameter than the dual upper IBOP 20 and may be sized to fit within the drill string or casing string in the wellbore, so that it can be detached from the upper IBOP 20 and deployed into the wellbore as needed.
- the single-end loading capability of the upper IBOP 20 enables this flexibility in sizing of the lower IBOP 300.
- the single-end loading capability of the dual upper IBOP 20 also provides flexibility with other design features at the lower end 47 of the IBOP.
- an internal shoulder or step 64 is provided between the threads 47B and the second valve 24.
- the lower fixed seat 35 rests against this step 64.
- the diameter of the opening through the step 64 may be smaller than the diameter of the valves 22, 24 and the opening 46A.
- the single-end loading capability of the IBOP 20 also enables the two ball valves 30, 32 to have the same configuration with respect to the borehole.
- Each ball valve 30, 32 includes a ball 36, 37 trapped between two seats, as described above.
- the fixed seat 34, 35 is inserted first, followed by the ball 36, 37, followed by the floating seat 42, 43.
- the floating seat is oriented toward the opening through which the valve was inserted, between that opening and the ball. If the two valves 30, 32 were inserted through different openings, for example the upper valve through an upper opening and the lower valve through a lower opening, then the two floating seats would face away from each other, toward the respective openings, and the two fixed seats would face toward each other.
- Such a configuration would result in one valve having a fixed seat toward the wellbore, and the other valve having a floating seat toward the wellbore.
- valves 30, 32 of the single-end loading IBOP 20 in Figure 4 are both inserted through the upper opening 46A, and therefore both floating seats are toward the top, and both fixed seats toward the bottom. Both valves 30, 32 have the same orientation with respect to the borehole.
- both valves 30, 32 include a fixed seat toward the borehole (toward the lower end 47 of the IBOP) and a floating seat toward the top drive (toward the upper end 46 of the IBOP). If the valve is needed to control a pressure kick, the pressure will originate from the borehole side, lifting the ball 36, 37 off of the fixed seat 34, 35 and pressing it against the floating seat 42, 43. In both cases, the ball is pressed against its respective floating seat, since both floating seats are toward the top end 46. Therefore, the single-end loading capability of the IBOP 20 enables both of the dual valves 22, 24 to have the same configuration (the orientation of the fixed and floating seats) with respect to the high-pressure side, which simplifies design and testing of the valves.
- the single-end loaded dual upper IBOP 20 includes nesting components, which reduce the overall length of the IBOP 20.
- the floating seat 43 for the valve 24 and the fixed seat 34 for the valve 22 are nested, with the seats overlapping each other as noted at area A.
- the seats 43, 34 each have a stepped shape, with the floating seat 43 fitting within the fixed seat 34.
- the spring 38 is placed between the two seats, to urge the floating seat 43 toward the lower ball 37.
- This nested, overlapping configuration reduces the overall axial length of the IBOP 20. Because both valves 22, 24 are loaded into the housing 23 from the same opening, the seats 43, 34 of the two valves can be configured to nest together.
- the upper floating seat 42 and the retainer ring 71 have a nested configuration, overlapping as noted at area B.
- the overall length of the IBOP 20 as shown in Figure 4 is about 24-30 inches.
- the upper end 46 of the IBOP 20 includes internal threads 46B, which in one embodiment are configured to mate with the output shaft 26 of the top drive 12.
- the lower end 47 includes internal threads 47B, which in one embodiment are configured to mate with the drill string, or with a lower IBOP valve such as the lower single IBOP 300 ( Figure 8 ).
- FIG. 5 Another embodiment of a dual upper IBOP 20' is shown in Figure 5 .
- the IBOP 20' includes two valves 22, 24 within a single housing 23.
- the valves 22, 24 are ball valves.
- the first valve 22 is shown in the open position, while the second valve 24 is closed.
- the closed valve 24 has been rotated to move a solid side of the ball 37A into the mud flow path 28, blocking the path.
- Each valve can be rotated through 90 degrees between the open and closed positions.
- Figure 5 also shows an external actuator assembly 166 that is used to operate the valves, to open or close them.
- the actuator assembly 166 includes an actuator shell or sleeve 68 mounted around the housing 23, externally of the two valves 22, 24, and two external crank assemblies 44A, 44B (one on the left side of the figure and one on the right) associated with each valve.
- the external crank assemblies 44A, 44B for each valve are coupled on one end to the respective internal crank assembly 41 A, 41B and at the other end to the actuator sleeve 68.
- the actuator sleeve 68 moves up and down with respect to the housing 23, to operate the crank assemblies to rotate the valves between the open and closed positions. This is just one of many types and configurations of actuators, however, and other arrangements and configurations of actuators may be used with the dual upper IBOP. Further details of the actuator assembly are described below.
- FIGS 6-7 show a dual upper IBOP 20" with an actuator assembly 66, according to an embodiment of the invention.
- the actuator assembly 66 is used to operate the valves 22, 24 within the dual upper IBOP 20". Both valves can be operated by a single actuator assembly.
- the actuator assembly 66 controls both valves. Because the IBOP 20" is a dual valve assembly with two valves, rather than a single IBOP with only one valve, the actuator assembly 66 is used to perform two functions -- to hold one of the two valves in a fixed (typically open) position, and to operate the other valve to open or close it.
- the first valve 22 may be acting as the primary valve
- the second valve 24 may be the back-up valve.
- the actuator assembly holds both valves open, allowing mud or other fluid flow through the IBOP.
- the actuator assembly 66 can be operated to close the first (primary) valve while continuing to hold the second valve open.
- the actuator assembly 66 is designed to operate either valve while maintaining the other valve locked in the open position. In an emergency event, both valves can be closed.
- the actuator assembly 66 includes an actuator sleeve 68 that is mounted externally of the IBOP housing 23 and that is slidable with respect to the housing 23.
- the actuator sleeve 68 engages four external cranks 54A, 54B, 55A, 55B coupled to the two valves 22, 24, respectively.
- Two of the cranks 54A and 55A are visible from the view in Figure 6 , and the other two are on the opposite side of the dual upper IBOP 20".
- the description below refers to the visible cranks 54A and 55A in Figure 6 , and it should be understood that the same operations are taking place on the opposite side with cranks 54B and 55B.
- cranks 54A, 55A When the sleeve 68 is translated between the upper and lower ends of the IBOP 20", the sleeve rotates one of the two cranks 54A, 55A to open or close one of the valves, while retaining the other crank in a fixed position.
- the cranks 54A, 55A are shown in Figure 6 with their arms 57 pointed downwardly and to the right (in the orientation of the figure). In this position, both valves 22, 24 are open.
- the crank To close one of the valves, the crank is rotated through 90 degrees in the counter-clockwise direction, until the crank arm is pointed upwardly and to the right.
- the cranks 54A, 55A extend externally of the housing 23 to engage the actuator sleeve 68.
- the cranks 54A, 55A include a projection such as an internal arm 59 (shown in Figure 5 ) that engages the hexagonal hole 50 of the internal crank assemblies 41 A, 41B (shown in Figure 4 ).
- rotation of the external cranks 54A, 55A is transmitted to the internal crank assemblies 41 A, 41 B.
- the internal crank assemblies 41 A, 41 B fit into a slot in the outer surface of the balls, as described above, and thus rotation of the internal cranks causes a corresponding rotation of the balls, thus rotating the balls into the open or closed position.
- the external cranks 54A, 55A pass through a slot 73 in the actuator sleeve 68 to engage the valves 22, 24.
- the actuator assembly 66 is configured to operate the first, primary valve between the open and closed positions while maintaining the second, back-up valve in the open position.
- the actuator sleeve 68 is provided with a plate 70 bolted to the sleeve.
- the plate includes a recess 72 that receives an end of the arm 57 of the first crank 54A, and a stop or wall 74 that contacts an end of the arm 57 of the second crank 55A.
- the wall 74 thus prevents the crank 55A from rotating the second valve 24 into the closed position.
- the wall 74 retains the second valve 24 in the open position.
- the recess 72 and its side edges or arms 72A engage the arm of the first crank 54A and rotate it counter-clockwise.
- the recess 72 is deep enough to allow the crank to rotate through its arc. This in turn rotates the first valve 22 into the closed position.
- the sleeve 68 can be translated back down toward the second end 47 to open the first valve, while still holding the second valve open.
- the plate 70 can be removed from the sleeve 68 by removing the screws 75. With the plate removed, either crank 54A, 55A can be rotated to the desired position, opening or closing the valves 22, 24. When the cranks and valves are in the desired position, the plate 70 is replaced.
- the plate can be attached to the sleeve 68 in either of two orientations -- with the recess 72 engaging the upper crank 54A or engaging the lower crank 55A.
- the plate 70 can operate either crank while holding the other crank in a fixed position, and the fixed position can be chosen to be either open or closed. Typically the fixed position will be open so that the back-up valve is held open while the primary valve is operated.
- the actuator sleeve 68 includes a groove or channel 76, which can be located at any convenient position along the sleeve.
- the groove 76 could alternatively be provided as a space between two rims or flanges 78.
- the groove 76 receives a yoke 17 (see Figure 9 ) which is in turn connected to a hydraulic cylinder or other actuator.
- the cylinder and yoke move the sleeve 68 up and down with respect to the housing 23, to operate the crank that is engaged with the recess 72.
- the groove 76 and yoke 17 are provided to accommodate the rotation of the IBOP 20", as the IBOP is rotated along with the top drive output shaft 26 and the drill string.
- the yoke 17 does not rotate with the IBOP.
- the groove 76 and rims 78 allow translational force from the yoke 17 to be transmitted to the sleeve 68 while isolating the yoke 17 from rotation of the IBOP.
- the cylinder can be controlled remotely, such that operation of the cylinder, actuator sleeve, and valves can be controlled from a remote location.
- a controller may be provided to send signals between a remote control station and the cylinder.
- the non-operational crank (the crank held in a fixed position by the wall 74) can be replaced by a plate such as the plate 81 shown in Figure 6A .
- the plate 81 includes a protrusion such as a male hexagonal arm 83 that engages the female hexagonal (or other shaped) hole 50 in the internal crank assembly of one of the two valves (see Figure 4 ).
- the plate 81 is bolted to the housing 23 with the male hexagonal arm 83 engaging the female hexagonal hole 50, to fix the position of the valve and prevent the valve from rotating.
- the actuator 66 can be used to operate the other crank, to rotate the other valve between the open and closed positions.
- the plate 81 provides a secure way to fix the position of the back-up valve, such as to lock it into the open position. In this instance, the wall or stop 74 is not needed, as the plate 81 replaces the non-operating crank 55A. To operate the back-up valve, the plate 81 is removed and replaced with the crank (such as crank 55A), which can then be operated by the actuator sleeve 68 to rotate the valve.
- the crank such as crank 55A
- the IBOP 20" with actuator assembly 66 is also shown in Figure 7 .
- This figure shows the dual crank assemblies provided on each side of the IBOP, and indicates the location of the four cranks 54A,B and 55A,B.
- each valve includes two crank mechanisms, one on each side of the valve.
- a cover plate 80 attached to the sleeve 68 to cover the cranks, the plate 70, and the screws 75. This cover plate 80 is provided to protect these components and to prevent loose components from falling to the rig floor.
- the cover plate 80 may include one or more windows 82 to view the position of the cranks.
- Figure 8 shows a dual upper IBOP 200 with actuator assembly 66.
- the actuator assembly is shown with the recess 72 of the plate 70 engaging the lower crank 55A.
- the dual upper IBOP 200 is attached at its lower end to a single lower IBOP valve 300, which is provided as required by regulation.
- the single lower IBOP 300 may be attached to the dual upper IBOP 200 via the lower threads 47B (see Figure 4 ).
- clamps such as the clamps 84 shown in Figure 8 may also be provided to secure the connection between the IBOPs 200, 300.
- FIG. 9 Another embodiment of an actuator assembly 66' is shown in Figure 9 .
- the cranks 54A, 55A for the upper and lower valves are offset about the circumference of the IBOP.
- Two separate plates 70 are provided, one to engage each crank.
- Each plate 70 includes one side with a wall 74 and an opposite side with a recess 72. The plate can be removed and reversed to place either the wall or the recess in engagement with the crank.
- the crank can be positioned in the desired position to open or close the respective valve, and the plate can then be used to either operate the crank or to retain the crank in the desired position.
- Figure 9 the recess 72 engages the upper crank 54A, which is currently in the open position (pointed down), and the wall 74 engages the lower crank 55A, which is also in the open position (pointed down).
- Figure 9 also shows the yoke 17 with two rollers 19 that fit into the groove 76 to transmit translational movement from the yoke 17 to the sleeve 68 while the sleeve 68 is rotating.
- FIG. 10 Another embodiment of an actuator assembly 166 is shown in Figure 10 .
- This actuator assembly includes a sleeve 68, internal crank mechanisms 41A, 41B, external crank assemblies 44A, 44B, and external cranks 54, 55 (only one of which, 55B, is shown in the figure).
- the external crank 55B is coupled to the other crank assemblies through several components, and an exploded view is shown in Figure 10 .
- the engagement of the sleeve 68 and the cranks 54, 55 utilizes a rotation of a shaft 60 to rotate each valve 22, 24.
- crank housing actuator assemblies shown generally as 44A and 44B (a pair for each valve 22, 24).
- Each assembly engages an internal assembly 41A, 41B, which includes a crank 51 that is attached to each ball.
- Each crank 51 engages the ball 36 such that rotation of the crank 51 causes rotation of the ball.
- Each crank 51 has a hexagonal hole 50 facing outwardly, away from the ball.
- the external crank assembly 44A, 44B includes a hexagonal shaft end 48 that mates with the hexagonal holes 50. The mating hexagonal shape of the shaft end 48 and the hole 50 causes rotation of the shaft end 48 to be transmitted to the crank 51, and thereby to the ball.
- the shaft end 48 is rotated by movement of the shell 68 and crank 54, as described further below.
- the vertical motion of the actuator shell 68 is integrated with cam rollers 52A sliding in a horizontal slot 52B. Movement of the shell 68 thus causes an angular movement of the crank 55B. This movement in turn rotates the shaft 60 and the shaft end 48, causing a rotation of the crank 51 and the attached ball. Thus the angular motion of the crank arm assemblies rotates the balls 36, 37 to open and close the valves.
- the rotation of the crank 55B of the crank assembly 44B is passed through a first threaded sleeve 56 through a hex drive 58 and threaded shaft 60, which then passes through a threaded sleeve 62 to engage the crank assembly 44B and thus the crank 51 and ball 37.
- This crank system assembly (44B, 48, 62, 60, 58, 56, 52A, 52B, 55B) is installed over the dual ball upper IBOP valve assembly.
- An actuator arm assembly such as a yoke shaped arm is provided with two cam rollers that fit into a groove in the actuator sleeve 68, to transmit motion to the sleeve 68 (see Figure 9 ).
- a hydraulic cylinder may be mounted on the rig, for example on a pipe handler frame (see Figure 2 ), through a linkage to slide the actuator sleeve vertically up and down.
- the crank arm assemblies with the cam rollers are captured by a retainer on the crank housing assemblies preventing them from sliding out but allow them the freedom to rotate.
- the vertical motion of the actuator shell with the crank arm assembly cam rollers sliding horizontally in the slots generates a circular motion applying a torque to rotate the ball valve through 90 degrees either clockwise or counterclockwise directions, to open and close the valve as desired.
- the actuator assembly 166 may be used to operate one valve while retaining the other valve open or closed.
- the shaft 60, sleeve 62, and end 48 can be connected to the hexagonal hole 50 to transmit rotation from the crank 55B to the ball 37.
- these components can be disengaged such that movement of the actuator sleeve 68 and rotation of the crank 55B does not operate the valve, thus allowing the sleeve 68 to move without actuating the back-up valve.
- the assembly includes the threaded adjustment sleeve 62 running over the threaded drive shaft 60.
- a hexagon drive on the end of the drive shaft would screw the threaded adjustment sleeve 62 in and out clockwise and counterclockwise, engaging and disengaging the crank assemblies 44A, 44B of the first and second valves, respectively.
- the engaged first valve becomes the functional valve and the disengaged second valve becomes the nonfunctional, back-up valve which is maintained open.
- the threaded adjustment sleeves 62 are automatically locked in that position against the hexagonal hole in the crank housing assembly.
- the threaded adjustment sleeves 62 would have two distinct positions - either screwed in clockwise to a stop to engage or screwed out counter clockwise to a stop to disengage the cranks 44A, 44B.
- the crank that is engaged with the respective crank arm assembly would then either open or close the respective ball valve.
- the crank arm assembly of the disengaged and locked second valve would continue to go through their angular motions freely similar to the crank arm assemblies of the engaged and operating first valve.
- the disengaged feature of the threaded adjustment sleeves would keep the ball valve from operating and the locked feature would keep the ball valve from accidentally closing.
- Nylon inserts (not shown) in the threaded adjustment sleeves may provide sufficient friction to prevent inadvertent rotation of the ball when they are in their home positions.
- a method of assembling and disassembling a dual upper IBOP is provided. To assemble the valves, break-out the existing single upper IBOP valve from the drill string (as done routinely) and install a new dual upper IBOP valve assembly with the new actuator shell 68. The new dual upper IBOP is installed by engaging the upper and lower threads 46B, 47B with the drill string or top drive and/or by clamping the IBOP to the components of the drill string. Once the dual upper IBOP is installed, the actuator shell 68 is positioned over the dual upper IBOP valve assembly in the neutral position so that the horizontal slots for the crank assemblies are lined up with the center of each valve.
- the four crank housing sub-assemblies are installed and secured.
- One of the two valves is identified as the operational valve and the other valve as the back-up.
- the two threaded adjustment sleeves for the operational valve are screwed in clockwise to their stops.
- the other two threaded adjustment sleeves, for the non-operational back-up valve are retracted counter-clockwise to their stops.
- the plates 70 are attached with the recess 72 engaging the crank of the operational valve, and the wall 74 engaging the crank of the non-operational valve (or the plate 81 may be used).
- a method for operating an internal blowout preventer in a top drive drilling system includes providing an internal blowout preventer with a housing having first and second openings at opposite first and second ends of the housing, and loading first and second valves into the housing through the first opening.
- the actuator sleeve is then attached to the housing and coupled the actuator sleeve to the first and second valves.
- the method also includes configuring the actuator sleeve to operate the first valve, and configuring the actuator sleeve to maintain the second valve in a fixed position, such as the open position.
- the actuator sleeve can then be translated along the housing to operate the first valve.
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Description
- This disclosure relates to the field of oilfield drilling equipment. In particular, this disclosure is drawn to an internal blowout preventer of a top drive system used in drilling rigs for the discovery and production of hydrocarbons from the earth.
- Internal blowout preventers (IBOPs) are valves designed to contain down-hole pressure and prevent blowouts in high pressure drilling applications. The IBOP includes a valve that can be closed in order to contain fluid from flowing out of the well. Regulations in some geopolitical areas require two IBOPs (referred to as an upper IBOP and a lower IBOP) at the top of the well, for safety redundancy. Both the lower and the upper IBOP are tested periodically, such as weekly, to confirm that both valves hold a sufficient pressure without leaking. Other than this periodic testing, the lower IBOP valve is typically used only in the event of an emergency, such as a well blow-out. However, the upper IBOP valve is also used as a mud saver valve to contain hydrostatic or mud pump pressure from above. That is, each time a stand of pipe (typically three pipe segments threaded together) is added to the string and lowered into the wellbore, the upper IBOP is closed prior to disconnecting the top drive from the drill string, in order to contain the drilling fluid or mud flowing through the top drive. With the upper IBOP closed, the top drive is disconnected from the drill string and the entire assembly is raised to accept a new stand of pipe. Thus the upper IBOP valve may be cycled many times per day as a mud saver valve, in addition to weekly testing and emergency use.
- Due to this repeated cycling, the upper IBOP valve tends to be high maintenance, and has been known to fail in the field due to the turbulent and corrosive flow of mud or drilling fluid through the valve. Additionally, as mentioned above, both the upper and lower IBOP valves are subject to periodic hydrostatic pressure testing, and a test failure requires immediate replacement of the valve, leading to lost drilling time. The upper IBOP valve in particular is subject to frequent repair or replacement.
- A typical known IBOP assembly includes both a lower IBOP and an upper IBOP, each IBOP including a single blow-out preventer valve. The two IBOPs may be coupled together through multiple separate assemblies. In many cases, regulations require the redundancy of an upper and a lower IBOP, as a safety requirement. In use, the seals on these valves are subject to high strain and wear, causing frequent failure. Because a back-up valve is always required, if one of the valves fails (such as failing a weekly pressure test), the backup is then put in operation only until it is possible to shut down the drilling operation to repair or replace the first failed valve. When one of these valves fails, drill operations must be suspended while the entire IBOP unit is replaced or while repairs are performed. Neither of these options is particularly appealing, however, due to cost and loss of time on the drill site. Repair or replacement of an upper IBOP valve is a time consuming process.
- IBOP valves are important parts of a top drive system which is used to drill for oil and gas. Known top drive systems typically have an upper IBOP valve and a lower IBOP valve, as regulations require, which become parts of the drill string during drilling. Each IBOP typically has only a single valve. IBOP valves are used as pressure control valves in case of a pressure kick from the well bore. The upper and lower IBOPs are typically used in tandem to provide the required safety redundancy, which necessarily involves numerous additional pipe connections and steps, and adds additional length in the assembly. The upper IBOP valve is remotely operated and is also used as a mud saver valve when a drill string connection is broken to add a new section of drill pipe.
- Document
US 7 287 544 B2 discloses an internal blowout preventer in accordance with the features of the preamble of claim 1. The internal blowout preventer is a triple-valve internal blowout preventer having unitary construction. Each valve includes a tubular assembly having a central passageway with upper and lower seats mounted therein. -
Document GB 2 129 033 A - The invention provides for an internal blowout preventer for use in drilling operations with the features of claim 1. Embodiments of the invention are identified in the dependent claims.
- Accordingly, a dual upper IBOP valve is provided, having two ball valves within a single housing. This dual upper IBOP assembly provides a second redundancy in the system, by providing both a main upper IBOP valve and a back-up upper IBOP valve. An actuator sleeve may be provided to operate crank mechanisms for each valve, to open or close the valve as necessary. A dual upper IBOP valve with a quick engagement crank mechanism allows the upper IBOP to continue to be used even after failure of the first upper IBOP valve, by switching to the second upper IBOP valve. A dual upper IBOP can improve the drilling situation considerably by allowing the rig crew to schedule repair work on the problematic valve to a convenient time, rather than needing an immediate emergency repair or replacement.
- The dual upper IBOP valve disclosed herein is an improvement over the existing single upper IBOP valve and can be used as a direct replacement of either a single upper IBOP valve (which does not provide the second redundancy) or two single upper IBOP valves connected in series (which add considerable length and additional connections to the assembly). In case of a failure of the first upper IBOP valve, the second upper IBOP valve in the dual upper IBOP can be used, thereby saving valuable drilling time until a repair or replacement procedure can be scheduled. The dual valves can be operated such that only one of the two valves in the dual upper IBOP valve is functional at a time, and the other is set up as a back-up valve. The dual upper IBOP valve is a candidate to improve performance, efficiency, and reliability of top drive systems.
- During drilling operations and under normal maintenance of equipment, it is a requirement that the upper and lower IBOP valves be periodically pressure tested to maintain credibility. If either IBOP fails the test, it is mandatory that a new valve be installed immediately, before drilling may resume, even if the other IBOP passes the test. This requirement is mandatory so that the system always operates with two fully functional valves, for safety redundancy. As the upper IBOP valve is used far more frequently than the lower IBOP valve, for mud saving, the upper IBOP valve is more likely to fail a pressure test due to repeated wear. Replacing or repairing an upper IBOP valve is very time consuming, and the valve test failure may occur at a critical time of the drilling program. With only a single upper IBOP valve, drilling must be stopped regardless of the timing so that the valve can be replaced. This situation may compromise safety to achieve the required results and may also incur considerable expenses and delay. With the use of a dual upper IBOP, this kind of an emergency will be, for the most part, eliminated, as the back-up upper IBOP valve may be used until a repair or replacement can be scheduled at a convenient and safe time. The system can continue to operate with the required safety redundancy, by operating with the back-up upper IBOP valve and the lower IBOP valve, until the main upper IBOP valve can be repaired.
- In the above described situation, a top drive system equipped with a new dual upper IBOP valve with its unique design allows the drilling crew to quickly switch to the back-up upper IBOP valve and continue drilling. The switch to the backup upper IBOP valve is achieved by disengaging the faulty upper IBOP valve and engaging the back-up upper IBOP valve with minimal effort and time. This capability allows the replacement or repair of the dual upper IBOP valve to be scheduled and performed when convenient.
- According to the invention, a dual internal blowout preventer for oilfield drilling operations includes two complete independent blowout preventer assemblies independently operable in a single housing. In one embodiment, at least one of the internal blowout preventer assemblies is adapted to be operated remotely. In one embodiment, both of the internal blowout preventers are adapted to be operated remotely. In one embodiment, a single-end loaded, dual ball, upper internal blowout valve is provided for drilling operations. A quick change crank mechanism is also provided for use with a single end loading, dual ball, upper internal blowout valve.
- The internal blowout preventer (IBOP) for use in drilling operations includes a housing having first and second openings at opposite first and second ends of the housing, and having a flow passage between the openings. The IBOP also includes first and second valves located in the flow passage in the housing. Each valve is movable between an open position in which the flow passage is open and a closed position in which the flow passage is closed. The IBOP also includes an actuator assembly coupled to the housing for independently operating the first or second valve. The first and second valves are received into the housing through the first opening.
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Figure 1 is a partial section and schematic view of an arrangement of a drilling rig for drilling boreholes into the earth according to an embodiment of the invention. -
Figure 2 is a partial side and partial cross-sectional view of a top drive drilling system illustrating the arrangement of a dual upper internal blowout preventer, and its placement on the drilling rig, according to an embodiment of the invention. -
Figure 3 is another partial section view showing in greater detail the arrangement of selected components of the top drive drilling rig ofFigure 2 and in particular one arrangement of the dual upper internal blowout preventer. -
Figure 4 is a partial cross-sectional view of a dual ball upper internal blowout preventer according to an embodiment of the invention. -
Figure 5 is cross-sectional view of a dual ball upper internal blowout preventer with a quick change crank mechanism in another embodiment of the invention. -
Figure 6 is a front view of a dual upper internal blowout preventer with actuator assembly, according to an embodiment of the invention. -
Figure 6A is a front and side view of a plate for use with a dual upper internal blowout preventer, according to an embodiment of the invention. -
Figure 7 is an upper perspective view of a dual upper internal blowout preventer with actuator assembly, according to an embodiment of the invention. -
Figure 8 is an upper perspective view of a dual upper internal blowout preventer with actuator assembly, connected to a lower internal blowout preventer valve, according to an embodiment of the invention. -
Figure 9 is a partial side view of a dual upper internal blowout preventer with crank assembly, according to an embodiment of the invention. -
Figure 10 is an exploded cross-sectional view of a crank actuator assembly for a dual ball upper internal blowout preventer according to an embodiment of the invention. -
Figure 1 shows adrill string 2 suspended by aderrick 4 for drilling a borehole 6 into the earth for minerals exploration and recovery, and in particular the recovery of petroleum or natural gas. A bottom-hole assembly (BHA) 8 is located at the bottom of the borehole 6 and comprises adrill bit 10. In directional drilling, theBHA 8 may have a downholesteerable drilling system 9. - As the
drill bit 10 rotates down hole, it cuts into the earth allowing thedrill string 2 to advance, forming the borehole 6. For the purpose of understanding how these systems may be operated, for the type ofsteerable drilling system 9 illustrated inFig. 1 , thedrill bit 10 may be one of numerous types well known to those skilled in the oil and gas exploration business. This is just one of many types and configurations ofbottom hole assemblies 8, however, and is shown only for illustration. There are numerous downhole arrangements and rig and equipment configurations possible for use for drilling boreholes into the earth withtop drive systems 12, and the present disclosure is not limited to the particular configurations as detailed herein. -
Figures 2 and3 are side views of components of a drilling rigtop drive system 12 according to an embodiment of the present invention. A dual ball upper internal blowout preventer (IBOP) 20 according to an embodiment of the present invention is mounted to the rig along with other components of the top drive drilling rig, including ayoke 17, apipe handler frame 15, and a hydraulic cylinder 13 (Figure 2 ). The dual ballupper IBOP 20 includes twoball valves upper IBOP valve 22 and the secondupper IBOP valve 24 are both adapted for controlling well pressure and drilling mud flow.Figure 2 shows the relative location of theupper IBOP valves lower IBOP 300 withsingle ball valve 301 is connected below the dualupper IBOP 20. Below thelower IBOP 300 is a bell-mouth 302 which receives the top end of a pipe segment or pipe stand. - As shown in
Figure 3 , the dual ballupper IBOP 20 is connected to themain output shaft 26 of thetop drive system 12, and is exemplary of one manner in which this dual ballupper IBOP 20 may be implemented on a drill rig with atop drive system 12. In one embodiment theIBOP 20 is threaded directly to theoutput shaft 26. Theoutput shaft 26 is rotated by thetop drive 12. The dual ballupper IBOP 20 is not limited only to these types of drilling systems. The dual ballupper IBOP 20 with first andsecond valves top drive system 12 and forms a part of the drill string, as indicated inFigures 2 and3 . - Turning to
Figure 4 , a detailed view of a dualupper IBOP 20 is shown according to an embodiment of the invention. The dualupper IBOP 20 includes twoseparate valve assemblies upper IBOP 20 includes amud flow passage 28 through the center of the IBOP, along the central longitudinal axis of the IBOP. Eachvalve assembly IBOP 20. The dualupper IBOP 20 may replace an existing single upper IBOP valve in a typical drill rig. Further details of the dualupper IBOP 20 are described below, including the arrangement of thevalves - In one embodiment, the dual upper
IBOP valve assembly 20 consists of two substantiallyindependent valve assemblies single IBOP housing 23. In one embodiment, the twoIBOP valve assemblies ball valve valves first valve 22 may be located at the top, above the second valve, and thesecond valve 24 may be located at the bottom, or vise versa. When the dualupper IBOP 20 is installed, one valve is identified as the primary valve, and the other valve as the back-up valve. Either valve may function as the primary valve. In one embodiment, thefirst valve 22 is the primary functioning IBOP valve, and thesecond valve 24 is the back-up IBOP valve. - As mentioned, the
valves ball valves Figure 4 . In one embodiment, eachball valve valves upper IBOP assembly 20 occupies the same space in the drill string as an existing single upper IBOP valve. Thus, an existing drilling rig with a single upper IBOP valve can be retrofitted with a dualupper IBOP 20 by simply removing the single upper IBOP valve and replacing it with the dualupper IBOP 20, without adding any additional length or width to the drill string. - The
ball valves spherical ball 36, 37. Each ball is seated between afixed seat seat balls 36, 37 to trap the balls inside theIBOP housing 23. The fixed seats 34, 35 are fixed to theIBOP housing 23 such as by threads or other mechanical fasteners. The floating seats 42, 43 are biased against other components to apply a force to therespective ball 36, 37 to hold the ball in place between the two seats. In one embodiment, one ormore springs 38, such as a wavy circular spring or other type of spring, urges against the floatingseats spherical ball 36, 37. The spring and floating seat thereby urge the ball against the fixedseat ball 36, 37 from the respective fixedseat seat seat ball 36, 37 against the fixedseat - A
mud flow passage 28 through the center of the IBOP continues through the ball and seat components. Eachball 36, 37 includes abore 40 through the ball, and the bore can be aligned with themud flow passage 28 through the IBOP to allow mud flow. The ball can be rotated through 90 degrees to move a solid side of the ball into themud flow passage 28, blocking further passage of mud or other fluid through the IBOP 20 (shown inFigure 5 ). - Each
ball 36, 37 is connected to two internal crank assemblies, one on each side of the ball, identified as 41A and 41B respectively. It should be noted that in other embodiments, each ball may be connected to only one crank assembly. These internal crankassemblies housing 23. Eachassembly universal coupling 53. Thecoupling 53 fits into a slot in the side of each ball. Each crank 51 has ahexagonal opening 50 on the outer side, facing away from the ball, for engagement with an external crank assembly which is used to rotate the ball between open and closed positions, as described in more detail below. In other embodiments, theopening 50 can take other suitable shapes other than hexagonal, such as the shape of a square, triangle, or star. - As mentioned above, in one embodiment, the dual
upper IBOP 20 includes twovalves single housing 23. Thesingle housing 23 reduces the number of external connections or couplings that would otherwise be needed to connect two separate valve assemblies together. Thehousing 23 includes anupper end 46 and alower end 47. Theupper end 47 is toward thetop drive system 12, and thelower end 47 is toward the borehole 6. - Both
valve assemblies 22, 24 (including the valve and associated seats, springs, seals, and other components) can be loaded into thehousing 23 from the same end, in one embodiment theupper end 46. That is, the dual upperIBOP valve assembly 20 has the capability of being assembled from one end of thehousing 23, and as such be characterized as a "single end loading" dual upper IBOP valve. This capability is shown inFigure 4 , where bothvalves housing 23 through theupper end 46. The upper and lower ends 46, 47 each have anopening mud flow passage 28 through the IBOP. Each opening may haveinternal threads opening 46A and themud flow passage 28 through theupper end 46 are wide enough in diameter to receive thevalves valve 24 can be received into theIBOP housing 23 through theopening 46A, arranged betweenseats other valve 22 can be loaded into the IBOP and seated above thelower valve 24. Aretainer ring 71 is provided above thevalve 22, capturing thespring 38 between thering 71 and the floatingseat 42. The diameter of theopening 46A is selected to be wide enough to receive these valves and seats and corresponding components into thehousing 23. It should be noted that the IBOP can be designed to provide single-end loading from either theupper end 46 or thelower end 47. The embodiment ofFigure 4 provides loading from theupper end 46. In either case, the two valves are both loaded from the same end, and are functionally configured in the same way (as described in more detail below). - Due to the single end loading capability, the
opening 47A at thelower end 47 of the IBOP is not limited by the size of thevalves valves opening 46A at the upper end, the diameter of theopening 47A at the lower end is not constrained by a minimum size to receive the valves. Instead, the diameter of thelower opening 47A is free to be smaller than thevalves lower opening 47A to be sized for a desired component below theIBOP 20. For example, in one embodiment, a lower single IBOP assembly 300 (shown inFigure 8 ) may be attached to thelower end 47 of the dualupper IBOP 20, between theIBOP 20 and the drill string. Thelower IBOP valve 300 provides the required regulatory redundancy for safety. In one scenario, thelower IBOP 300 may be smaller in diameter than the dualupper IBOP 20 and may be sized to fit within the drill string or casing string in the wellbore, so that it can be detached from theupper IBOP 20 and deployed into the wellbore as needed. The single-end loading capability of theupper IBOP 20 enables this flexibility in sizing of thelower IBOP 300. - The single-end loading capability of the dual
upper IBOP 20 also provides flexibility with other design features at thelower end 47 of the IBOP. For example, in the embodiment shown inFigure 4 , an internal shoulder or step 64 is provided between thethreads 47B and thesecond valve 24. The lower fixedseat 35 rests against thisstep 64. The diameter of the opening through thestep 64 may be smaller than the diameter of thevalves opening 46A. - The single-end loading capability of the
IBOP 20 also enables the twoball valves ball valve ball 36, 37 trapped between two seats, as described above. When the valve is assembled, the fixedseat ball 36, 37, followed by the floatingseat valves - By contrast,
valves end loading IBOP 20 inFigure 4 are both inserted through theupper opening 46A, and therefore both floating seats are toward the top, and both fixed seats toward the bottom. Bothvalves Figure 4 , bothvalves lower end 47 of the IBOP) and a floating seat toward the top drive (toward theupper end 46 of the IBOP). If the valve is needed to control a pressure kick, the pressure will originate from the borehole side, lifting theball 36, 37 off of the fixedseat seat top end 46. Therefore, the single-end loading capability of theIBOP 20 enables both of thedual valves - In one embodiment, the single-end loaded dual
upper IBOP 20 includes nesting components, which reduce the overall length of theIBOP 20. For example, as shown inFigure 4 , the floatingseat 43 for thevalve 24 and the fixedseat 34 for thevalve 22 are nested, with the seats overlapping each other as noted at area A. Theseats seat 43 fitting within the fixedseat 34. Thespring 38 is placed between the two seats, to urge the floatingseat 43 toward thelower ball 37. This nested, overlapping configuration reduces the overall axial length of theIBOP 20. Because bothvalves housing 23 from the same opening, theseats seat 42 and theretainer ring 71 have a nested configuration, overlapping as noted at area B. In one embodiment, the overall length of theIBOP 20 as shown inFigure 4 is about 24-30 inches. - The
upper end 46 of theIBOP 20 includesinternal threads 46B, which in one embodiment are configured to mate with theoutput shaft 26 of thetop drive 12. Thelower end 47 includesinternal threads 47B, which in one embodiment are configured to mate with the drill string, or with a lower IBOP valve such as the lower single IBOP 300 (Figure 8 ). - Another embodiment of a dual upper IBOP 20' is shown in
Figure 5 . The IBOP 20' includes twovalves single housing 23. In the embodiment shown, thevalves first valve 22 is shown in the open position, while thesecond valve 24 is closed. Theclosed valve 24 has been rotated to move a solid side of theball 37A into themud flow path 28, blocking the path. Each valve can be rotated through 90 degrees between the open and closed positions.Figure 5 also shows anexternal actuator assembly 166 that is used to operate the valves, to open or close them. As shown inFigure 5 , theactuator assembly 166 includes an actuator shell orsleeve 68 mounted around thehousing 23, externally of the twovalves assemblies external crank assemblies assembly actuator sleeve 68. Theactuator sleeve 68 moves up and down with respect to thehousing 23, to operate the crank assemblies to rotate the valves between the open and closed positions. This is just one of many types and configurations of actuators, however, and other arrangements and configurations of actuators may be used with the dual upper IBOP. Further details of the actuator assembly are described below. -
Figures 6-7 show a dualupper IBOP 20" with anactuator assembly 66, according to an embodiment of the invention. Theactuator assembly 66 is used to operate thevalves upper IBOP 20". Both valves can be operated by a single actuator assembly. Theactuator assembly 66 controls both valves. Because theIBOP 20" is a dual valve assembly with two valves, rather than a single IBOP with only one valve, theactuator assembly 66 is used to perform two functions -- to hold one of the two valves in a fixed (typically open) position, and to operate the other valve to open or close it. For example, thefirst valve 22 may be acting as the primary valve, and thesecond valve 24 may be the back-up valve. Initially, the actuator assembly holds both valves open, allowing mud or other fluid flow through the IBOP. In the event of a pressure kick, a test event, or a mud-saver function, theactuator assembly 66 can be operated to close the first (primary) valve while continuing to hold the second valve open. Thus theactuator assembly 66 is designed to operate either valve while maintaining the other valve locked in the open position. In an emergency event, both valves can be closed. - As shown in
Figure 6 , theactuator assembly 66 includes anactuator sleeve 68 that is mounted externally of theIBOP housing 23 and that is slidable with respect to thehousing 23. To operate the valves, theactuator sleeve 68 engages fourexternal cranks valves cranks Figure 6 , and the other two are on the opposite side of the dualupper IBOP 20". The description below refers to thevisible cranks Figure 6 , and it should be understood that the same operations are taking place on the opposite side withcranks - When the
sleeve 68 is translated between the upper and lower ends of theIBOP 20", the sleeve rotates one of the twocranks cranks Figure 6 with theirarms 57 pointed downwardly and to the right (in the orientation of the figure). In this position, bothvalves - The
cranks housing 23 to engage theactuator sleeve 68. Thecranks Figure 5 ) that engages thehexagonal hole 50 of the internal crankassemblies Figure 4 ). As a result, rotation of theexternal cranks assemblies assemblies external cranks slot 73 in theactuator sleeve 68 to engage thevalves - The
actuator assembly 66 is configured to operate the first, primary valve between the open and closed positions while maintaining the second, back-up valve in the open position. To rotate one crank but not both cranks, theactuator sleeve 68 is provided with aplate 70 bolted to the sleeve. The plate includes arecess 72 that receives an end of thearm 57 of thefirst crank 54A, and a stop orwall 74 that contacts an end of thearm 57 of thesecond crank 55A. When theactuator sleeve 68 is moved toward theupper end 46 of the IBOP, theplate 70 moves with the sleeve, and thewall 74 slides along thesecond crank 55A, preventing thearm 57 of the crank from rotating counter-clockwise. Thewall 74 thus prevents thecrank 55A from rotating thesecond valve 24 into the closed position. Thewall 74 retains thesecond valve 24 in the open position. At the same time, as thesleeve 68 andplate 70 move upwardly, therecess 72 and its side edges orarms 72A engage the arm of the first crank 54A and rotate it counter-clockwise. Therecess 72 is deep enough to allow the crank to rotate through its arc. This in turn rotates thefirst valve 22 into the closed position. Thus, the first valve is closed while the second valve is held open. Thesleeve 68 can be translated back down toward thesecond end 47 to open the first valve, while still holding the second valve open. - The
plate 70 can be removed from thesleeve 68 by removing thescrews 75. With the plate removed, either crank 54A, 55A can be rotated to the desired position, opening or closing thevalves plate 70 is replaced. The plate can be attached to thesleeve 68 in either of two orientations -- with therecess 72 engaging the upper crank 54A or engaging the lower crank 55A. Thus, theplate 70 can operate either crank while holding the other crank in a fixed position, and the fixed position can be chosen to be either open or closed. Typically the fixed position will be open so that the back-up valve is held open while the primary valve is operated. - The
actuator sleeve 68 includes a groove orchannel 76, which can be located at any convenient position along the sleeve. Thegroove 76 could alternatively be provided as a space between two rims orflanges 78. Thegroove 76 receives a yoke 17 (seeFigure 9 ) which is in turn connected to a hydraulic cylinder or other actuator. The cylinder and yoke move thesleeve 68 up and down with respect to thehousing 23, to operate the crank that is engaged with therecess 72. Thegroove 76 andyoke 17 are provided to accommodate the rotation of theIBOP 20", as the IBOP is rotated along with the topdrive output shaft 26 and the drill string. Theyoke 17 does not rotate with the IBOP. Thegroove 76 andrims 78 allow translational force from theyoke 17 to be transmitted to thesleeve 68 while isolating theyoke 17 from rotation of the IBOP. The cylinder can be controlled remotely, such that operation of the cylinder, actuator sleeve, and valves can be controlled from a remote location. A controller may be provided to send signals between a remote control station and the cylinder. - As an alternative to the two
cranks Figure 6 , the non-operational crank (the crank held in a fixed position by the wall 74) can be replaced by a plate such as theplate 81 shown inFigure 6A . Theplate 81 includes a protrusion such as a malehexagonal arm 83 that engages the female hexagonal (or other shaped)hole 50 in the internal crank assembly of one of the two valves (seeFigure 4 ). Theplate 81 is bolted to thehousing 23 with the malehexagonal arm 83 engaging the femalehexagonal hole 50, to fix the position of the valve and prevent the valve from rotating. Theactuator 66 can be used to operate the other crank, to rotate the other valve between the open and closed positions. Theplate 81 provides a secure way to fix the position of the back-up valve, such as to lock it into the open position. In this instance, the wall or stop 74 is not needed, as theplate 81 replaces the non-operating crank 55A. To operate the back-up valve, theplate 81 is removed and replaced with the crank (such as crank 55A), which can then be operated by theactuator sleeve 68 to rotate the valve. - The
IBOP 20" withactuator assembly 66 is also shown inFigure 7 . This figure shows the dual crank assemblies provided on each side of the IBOP, and indicates the location of the fourcranks 54A,B and 55A,B. In this embodiment, each valve includes two crank mechanisms, one on each side of the valve. Also shown inFigure 7 is acover plate 80 attached to thesleeve 68 to cover the cranks, theplate 70, and thescrews 75. Thiscover plate 80 is provided to protect these components and to prevent loose components from falling to the rig floor. Thecover plate 80 may include one ormore windows 82 to view the position of the cranks. -
Figure 8 shows a dualupper IBOP 200 withactuator assembly 66. The actuator assembly is shown with therecess 72 of theplate 70 engaging the lower crank 55A. The dualupper IBOP 200 is attached at its lower end to a singlelower IBOP valve 300, which is provided as required by regulation. The singlelower IBOP 300 may be attached to the dualupper IBOP 200 via thelower threads 47B (seeFigure 4 ). Optionally, clamps such as theclamps 84 shown inFigure 8 may also be provided to secure the connection between theIBOPs - Another embodiment of an actuator assembly 66' is shown in
Figure 9 . In this case, thecranks separate plates 70 are provided, one to engage each crank. Eachplate 70 includes one side with awall 74 and an opposite side with arecess 72. The plate can be removed and reversed to place either the wall or the recess in engagement with the crank. The crank can be positioned in the desired position to open or close the respective valve, and the plate can then be used to either operate the crank or to retain the crank in the desired position. InFigure 9 , therecess 72 engages the upper crank 54A, which is currently in the open position (pointed down), and thewall 74 engages thelower crank 55A, which is also in the open position (pointed down).Figure 9 also shows theyoke 17 with tworollers 19 that fit into thegroove 76 to transmit translational movement from theyoke 17 to thesleeve 68 while thesleeve 68 is rotating. - Another embodiment of an
actuator assembly 166 is shown inFigure 10 . This actuator assembly includes asleeve 68, internal crankmechanisms assemblies external crank 55B is coupled to the other crank assemblies through several components, and an exploded view is shown inFigure 10 . In this embodiment, the engagement of thesleeve 68 and the cranks 54, 55 utilizes a rotation of ashaft 60 to rotate eachvalve - Referring now to
Figure 10 , disclosed, and externally mounted on thehousing 23, are four crank housing actuator assemblies shown generally as 44A and 44B (a pair for eachvalve 22, 24). Each assembly engages aninternal assembly crank 51 causes rotation of the ball. Each crank 51 has ahexagonal hole 50 facing outwardly, away from the ball. Theexternal crank assembly hexagonal shaft end 48 that mates with the hexagonal holes 50. The mating hexagonal shape of theshaft end 48 and thehole 50 causes rotation of theshaft end 48 to be transmitted to the crank 51, and thereby to the ball. Theshaft end 48 is rotated by movement of theshell 68 and crank 54, as described further below. - The vertical motion of the
actuator shell 68 is integrated withcam rollers 52A sliding in ahorizontal slot 52B. Movement of theshell 68 thus causes an angular movement of thecrank 55B. This movement in turn rotates theshaft 60 and theshaft end 48, causing a rotation of thecrank 51 and the attached ball. Thus the angular motion of the crank arm assemblies rotates theballs 36, 37 to open and close the valves. The rotation of thecrank 55B of thecrank assembly 44B is passed through a first threadedsleeve 56 through ahex drive 58 and threadedshaft 60, which then passes through a threadedsleeve 62 to engage the crankassembly 44B and thus the crank 51 andball 37. - This crank system assembly (44B, 48, 62, 60, 58, 56, 52A, 52B, 55B) is installed over the dual ball upper IBOP valve assembly. An actuator arm assembly such as a yoke shaped arm is provided with two cam rollers that fit into a groove in the
actuator sleeve 68, to transmit motion to the sleeve 68 (seeFigure 9 ). A hydraulic cylinder may be mounted on the rig, for example on a pipe handler frame (seeFigure 2 ), through a linkage to slide the actuator sleeve vertically up and down. The crank arm assemblies with the cam rollers are captured by a retainer on the crank housing assemblies preventing them from sliding out but allow them the freedom to rotate. The vertical motion of the actuator shell with the crank arm assembly cam rollers sliding horizontally in the slots generates a circular motion applying a torque to rotate the ball valve through 90 degrees either clockwise or counterclockwise directions, to open and close the valve as desired. - The
actuator assembly 166 may be used to operate one valve while retaining the other valve open or closed. As described above, theshaft 60,sleeve 62, and end 48 can be connected to thehexagonal hole 50 to transmit rotation from thecrank 55B to theball 37. However, these components can be disengaged such that movement of theactuator sleeve 68 and rotation of thecrank 55B does not operate the valve, thus allowing thesleeve 68 to move without actuating the back-up valve. The assembly includes the threadedadjustment sleeve 62 running over the threadeddrive shaft 60. A hexagon drive on the end of the drive shaft would screw the threadedadjustment sleeve 62 in and out clockwise and counterclockwise, engaging and disengaging thecrank assemblies adjustment sleeves 62 are automatically locked in that position against the hexagonal hole in the crank housing assembly. - The threaded
adjustment sleeves 62 would have two distinct positions - either screwed in clockwise to a stop to engage or screwed out counter clockwise to a stop to disengage thecranks - It would be apparent to those skilled in the art that many modifications of the dual upper
IBOP valve assembly 20 disclosed herein are possible without departing from the teachings of the present invention. For example, alternate components which are equivalent to components already described herein may be used. In addition it may be desirable to modify the disclosed valve assembly so it may have a different number of crank housing assemblies, each connected to an actuator shell and an actuator arm assembly. - A method of assembling and disassembling a dual upper IBOP is provided. To assemble the valves, break-out the existing single upper IBOP valve from the drill string (as done routinely) and install a new dual upper IBOP valve assembly with the
new actuator shell 68. The new dual upper IBOP is installed by engaging the upper andlower threads actuator shell 68 is positioned over the dual upper IBOP valve assembly in the neutral position so that the horizontal slots for the crank assemblies are lined up with the center of each valve. - Attention must be paid to match the orientation of the hexagonal holes (50) in the internal cranks with the hexagonal shafts (48) in the crank housing assemblies. Next, the four crank housing sub-assemblies are installed and secured. One of the two valves is identified as the operational valve and the other valve as the back-up. For
actuator assembly 166, the two threaded adjustment sleeves for the operational valve are screwed in clockwise to their stops. The other two threaded adjustment sleeves, for the non-operational back-up valve, are retracted counter-clockwise to their stops. Foractuator assembly 66, theplates 70 are attached with therecess 72 engaging the crank of the operational valve, and thewall 74 engaging the crank of the non-operational valve (or theplate 81 may be used). - When switching from the first valve to the second valve, to reverse functions of the two IBOP valves and utilize the back-up valve, the positions of the threaded adjustment sleeves or plates are reversed.
- A method for operating an internal blowout preventer in a top drive drilling system includes providing an internal blowout preventer with a housing having first and second openings at opposite first and second ends of the housing, and loading first and second valves into the housing through the first opening. The actuator sleeve is then attached to the housing and coupled the actuator sleeve to the first and second valves. The method also includes configuring the actuator sleeve to operate the first valve, and configuring the actuator sleeve to maintain the second valve in a fixed position, such as the open position. The actuator sleeve can then be translated along the housing to operate the first valve.
Claims (10)
- An internal blowout preventer (20) for use in drilling operations, comprising:a housing (23) having first and second openings (46A, 47A) at opposite first and second ends (46, 47) of the housing, and having a flow passage (28) between the openings (46A, 47A);first and second valves (22, 24) located in the flow passage (28) in the housing (23), each valve (22, 24) being movable between an open position in which the flow passage (28) is open and a closed position in which the flow passage (28) is closed; andan actuator assembly (66, 166) coupled to the housing (23) for independently operating the first or second valve (22, 24),wherein the first and second valves (22, 24) are received into the housing (23) through the first opening (46A),characterized in that each valve (22, 24) comprises a ball valve (30, 32) seated between a fixed seat (34, 35) and a floating seat (42, 43), and wherein, for each valve (22, 24), the fixed seat (34, 35) is between the valve (22, 24) and the second opening (47A) and the floating seat (42, 43) is between the valve (22, 24) and the first opening (46A).
- The internal blowout preventer of claim 1, wherein the second valve (24) and the second opening (47A) are separated by an internal step (64).
- The internal blowout preventer of claim 1, wherein the first and second openings (46A, 47A) comprise first and second diameters, respectively, and wherein the first and second diameters are different.
- The internal blowout preventer of claim 1, wherein the fixed seat (34) of the first valve (22) and the floating seat (43) of the second valve (24) are configured to overlap.
- The internal blowout preventer of claim 1, wherein the actuator assembly (66) comprises an actuator coupled to the housing (23) externally of the valves (22, 24), and wherein the actuator is coupled to at least one of the first and second valves (22, 24) such that movement of the actuator with respect to the housing (23) causes movement of the at least one valve (22, 24) between the open and closed positions.
- The internal blowout preventer of claim 5, wherein the actuator comprises a sleeve (68), and wherein the actuator assembly (66, 166) further comprises a first crank (54A, 54B) coupled between the sleeve (68) and the first valve (22), and a second crank (55A, 55B) coupled between the sleeve (68) and the second valve (24), such that translational movement of the sleeve (68) causes rotation of at least one crank (54A, 54B, 55A, 55B), causing a rotation of the corresponding valve (22, 24).
- The internal blowout preventer of claim 6, wherein the sleeve (68) comprises a recess (72) and a wall (74), and wherein the recess (72) engages the first crank (54A, 54B) and the wall (74) engages the second crank (55A, 55B), such that movement of the sleeve (68) causes a rotation of the first crank (54A, 54B) while preventing a rotation of the second crank (55A, 55B).
- The internal blowout preventer of claim 7, wherein the recess (72) and the wall (74) are provided on a plate (70) coupled to the sleeve (68), and wherein the plate (70) is reversible to engage the recess (72) with the second crank (55A, 55B).
- The internal blowout preventer of claim 5, wherein the actuator is remotely operable.
- The internal blowout preventer of claim 1, wherein the actuator (66, 166) assembly comprises a first crank (54A, 54B) coupled to the first valve (22) to rotate the first valve (22), a second crank (55A, 55B) coupled to the second valve (24) to rotate the second valve (24), a recess (72) engaging the first crank (54A, 54B) to rotate the first crank (54A, 54B), and a stop (74) engaging the second crank (55A, 55B) to prevent rotation of the second crank (55A, 55B).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US31278610P | 2010-03-11 | 2010-03-11 | |
PCT/US2011/027991 WO2011112869A2 (en) | 2010-03-11 | 2011-03-10 | Dual ball upper internal blow out preventer valve |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2545245A2 EP2545245A2 (en) | 2013-01-16 |
EP2545245B1 true EP2545245B1 (en) | 2017-04-26 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11709296.5A Active EP2545245B1 (en) | 2010-03-11 | 2011-03-10 | Dual ball upper internal blow out preventer valve |
Country Status (6)
Country | Link |
---|---|
US (1) | US8752653B2 (en) |
EP (1) | EP2545245B1 (en) |
BR (1) | BR112012022927B1 (en) |
CA (1) | CA2792753C (en) |
DK (1) | DK2545245T3 (en) |
WO (1) | WO2011112869A2 (en) |
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US11448026B1 (en) | 2021-05-03 | 2022-09-20 | Saudi Arabian Oil Company | Cable head for a wireline tool |
US11549329B2 (en) | 2020-12-22 | 2023-01-10 | Saudi Arabian Oil Company | Downhole casing-casing annulus sealant injection |
US11598178B2 (en) | 2021-01-08 | 2023-03-07 | Saudi Arabian Oil Company | Wellbore mud pit safety system |
US11828128B2 (en) | 2021-01-04 | 2023-11-28 | Saudi Arabian Oil Company | Convertible bell nipple for wellbore operations |
US11859815B2 (en) | 2021-05-18 | 2024-01-02 | Saudi Arabian Oil Company | Flare control at well sites |
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US11549329B2 (en) | 2020-12-22 | 2023-01-10 | Saudi Arabian Oil Company | Downhole casing-casing annulus sealant injection |
US11828128B2 (en) | 2021-01-04 | 2023-11-28 | Saudi Arabian Oil Company | Convertible bell nipple for wellbore operations |
US11598178B2 (en) | 2021-01-08 | 2023-03-07 | Saudi Arabian Oil Company | Wellbore mud pit safety system |
US12054999B2 (en) | 2021-03-01 | 2024-08-06 | Saudi Arabian Oil Company | Maintaining and inspecting a wellbore |
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Also Published As
Publication number | Publication date |
---|---|
WO2011112869A3 (en) | 2013-01-10 |
WO2011112869A2 (en) | 2011-09-15 |
WO2011112869A9 (en) | 2013-05-02 |
CA2792753A1 (en) | 2011-09-15 |
US20110226485A1 (en) | 2011-09-22 |
DK2545245T3 (en) | 2017-08-07 |
EP2545245A2 (en) | 2013-01-16 |
CA2792753C (en) | 2014-12-23 |
US8752653B2 (en) | 2014-06-17 |
BR112012022927A2 (en) | 2016-08-02 |
BR112012022927B1 (en) | 2020-01-14 |
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